Classification: Internal Use

Background:
As per VCM OPRN request, inspection performed for line # _____________ under piping circuit #
____________ to ascertain the present condition and accordingly carryout the remedial / replacement
activities during forthcoming T/A-2019. The following are the observations and recommendations:

Observations:
Visual Inspection.
1. Pitting corrosion (CUI) all around the circumference of pipe run, reducer (3" x 2"Ø) & Tee at
TML# 38, 39, 40, 41 & 43 with a depth of about 1.5 mm.
2. Note that, as per pipe class no insulation is specified, whereas all the piping of ethylene
header at VCM battery limit & near exchanger TE-1101 were found with insulation.
3. Sign of leak
4. Pitting corrosion (CUI) of about 1.5 mm at TML# 1 to 5. Note that, as per pipe class no
insulation is specified, whereas all the piping were found with insulation.
5. Sign of crack in the line / body of valve in-between TML # 3 & 5.
6. Sign of corrosion in the contact point locations in-between the pipeline and supports in
almost entire pipe run except the recently replaced portion. Refer the attached sketch for
details.
7. Note that the severity / extent of corrosion could not be assessed due to inaccessibility.
8. Paint flaking and corrosion of about 0.5 mm at pipe support location (PS # 09) at 1 O-clock
position in 6"Ø header pipe.
9. Dent of about 3ӯ with maximum depth of 1.5 mm at TML # 3.
10. Flange fasteners with short bolting (Location – Between TML # 1 & 2).
11. Pipeline was not resting on the supports near TML#6 and TML#10.
12. Deformation of the small-bore piping (tapping) at TML#3.
13. Paint damages in isolated locations of entire pipe run / welds.
14. Previous TML locations in almost entire pipe run is not painted and corroded.
15. No painting for the previously installed / replaced portion of the pipe from TML# 105 to 107
& 111 to 112.
16. Few U-clamps at pipe rack are missing / broken.
17. Corrosion Under Insulation (CUI) & paint damage / anomalies resulted in corrosion of weld
joints, pipes, elbows, flanges, fasteners & valves (TML # 9 to 62) at VCM battery limit.
18. Gland leak from isolation valve (LI-4142).
19. Abnormal vibration in associated piping of TV-1407.
20. Leak through line opening of the thinned area (50% of the circumference) as crack in
adjacent to the weld HAZ of 2ӯ elbow - TML# 03.
21. Note that the damaged / failure in horizontal portion of the line is due to dead leg corrosion
(stagnation of service deposits) in the upstream of SV-2102.
Classification: Internal Use

22. Paint damages in isolated locations and discoloration of entire pipe run / welds due to
contaminant.
23. Damaged insulation and its cladding (Location – TML # 1 to 5).
24. Damaged insulation and its cladding for entire pipe run.
25. All flange fasteners rusted / corroded.
26. U-clamp is missing / broken at TML#4.

Profile Radiography:
1. Profile radiography (RT) of three most pitted / severely corroded locations were performed
to measure the remaining thickness and estimated as about 1.0 mm (02 locations) and 2.2
mm ( 01 location) respectively.
UT thickness measurement:
1. UT thickness measurement of the established TMLs revealed the following:
a) Minimum of 2.7 mm against the design thickness of 2.9 mm in in TML # 4 (2ӯ portion).
b) Minimum of 2.7 mm against the design thickness of 2.9 mm in (2ӯ portion).
c) Minimum of 2.7 mm against the design thickness of 2.9 mm in (2ӯ portion).
Tmin = 1.8 mm (2ӯ) - Based on API guidelines for structural minimum thickness)
Note that the Short Term (ST) corrosion rate calculated as of 1.5 mm/yr. at TML # 188. Hence,
the derived remaining life is ____ yrs.
2. UT thickness could not be performed in adjacent to leak or TML# 1 to 3 due the access and
safety concern.
Recommendations:
1. Recommended to replace the portions TML#23 & 31 (flange to flange) of the line # 80-VC-
1301904-FF33A-IH50 during T/A-2019, in view of low thickness and high corrosion rate, low
remaining life and low original design thickness (DIN standard).
2. Replace the entire line (line # 50-SCL-1403531-BB31C) from flange to flange (TML# 1 to 10),
based on the reduction in thickness / high corrosion rate, number of years in service / aging
and low original design thickness (DIN standard) leak, low thickness ----, ------ and severe
corrosion cum thinning.
3. Replace the portion of the line # 50-EDC-1100801-BB31D from flange to flange at TML# 1 to
12, 29 to 34 and segment in between 35 to 39 in view of low thickness and CUI / pitting.
4. Replace the portion of the line (line # 50-SCL-1403531-BB31C) from flange to flange (TML#
1 to 10), in view of leak, low thickness ----, ------ and severe corrosion cum thinning.
5. Ascertain the requirement of insulation at piping in roof and accordingly repair the damaged
/ missing insulation.
6. Recommended to replace the other portions of the line # 50-EDC-1100801-BB31D during
T/A-2019, from flange to flange at TML# 1 to 12 and 29 to 34 in view of low thickness and
CUI / pitting.
Classification: Internal Use

7. Plan to replace the pipeline with low thickness at TML # 38 to 41 immediately, since
approached the minimum structural thickness.
8. Recommended to replace the other portions of line (TML# 01 – 05, 08 – 11, 13 – 15, 23 & 59
in the next available opportunity or T/A-2019. Any deferral in above replacement plan shall
be based on the condition assessment including contact point corrosion of the line after 01
yr. (from the date of present inspection) by UT thickness measurement, CR and remaining
life calculations.
9. Note that during the replacement, the minimum pipe wall thickness shall be SCH-40 for pipe
Ø from 2 to10” and SCH-80 for pipe Ø 1½ and smaller which is as per SABIC SES.
10. During replacement of the defective portions, the line shall be offered for inspection of
contact point corrosion by proper lifting and cleaning.
11. Provide proper U-clamp as per piping specifications. (Location: near TML#4).
12. Thickness monitoring of the entire line shall be performed after 02 yr. from the present
inspection to assess the C/R and remaining life.
13. Additional inspection (30%) of the lines of the piping circuit # PK22-01-VC-132 shall be
performed to ensure the condition, C/R and assess the next RBI frequency.
14. Based on the criticality of the line in the aspect of plant production and prevailing
observations such as contact point corrosion, reduction in thickness / corrosion pitting at
various locations, painting damages, number of years in service / aging, earlier repairs /
replacements as partial segments and low original design thickness (DIN standard), it is
suggested to replace the entire line at the available opportunity as per SABIC guidelines
(SES-P01-E01) with minimum thickness of Schedule-40 for all replacements of pipes having
diameter from 2 to 10 inches and minimum thickness of Schedule-80 for diameter less than
2 inches.
15. VCM-OPRN / MT-III ascertain the leak from gland of isolation valve (LI-4142) and perform
the remedial actions accordingly.
16. VCM-OPRN to ascertain the cause of vibration in system and take remedial action
accordingly.
17. Apply anti-corrosive compound flange fasteners.
18. Replace all the damaged cladding and insulation of line # 80-VC-1301904-FF33A.
19. Painting shall be carried out for the entire pipe run as per original specification.
20. Check and replace all the CS bolts in SS line (flange joints) to avoid galvanic corrosion.
21. VCM OPRN to offer the other portions line for thickness measurement after 06 months to
verify the recorded thickness and establish the exact corrosion rates / remaining life.
22. Replace all the damaged / thinned out cladding and insulation of line # ---------- and its
connected piping. Inspection in prior to replacement shall be offered for ascertaining any
CUI.
23. Recommended to replace the other portions of line (TML# 11 – 12 & 20 – 21 in the next
available opportunity or T/A-2019. Any deferral in above replacement plan shall be based
on the condition assessment of the line after 01 yr. (from the date of present inspection) by
UT thickness measurement, CR and remaining life calculations.
Classification: Internal Use

24. Additional inspection (20%) of the lines of the piping circuit # PK22-01-VF-142 shall be
performed to ensure the condition, C/R and assess the next RBI frequency.
25. Provide proper / missing piping supports near TML#6 and TML#10, as per piping
specifications.
26. Assess the piping elevation to avoid any stagnation of service in horizontal portion.
27. Ascertain the survey frequency of RD, as well as evaluate the provision of draining and
purging of upstream line to SV-2102, in order to avoid the stagnation of service and failure
of the line due to internal corrosion / thinning.
28. Replace the pipe run from TML# 27 to 57, which was noticed with temporary arresting with
worm wheel clamp / rubber and pitting due to CUI.
29. Replace the damaged PG, installed on reflux line near column.
30. Painting shall be carried out for the entire pipe run as per original specification.
31. Painting shall be carried out for the entire pipe run including contact point corrosion, as per
original specification. Inspection in prior to painting shall be offered for ascertaining the
condition contact point at support locations.
32. AED to assess the dent of about 3ӯ with maximum depth of 1.5 mm at TML # 3.
33. MT-III to rectify the short bolting in Flange fasteners (Location – Between TML # 1 & 2).
34. AED to assess the deformation of the small-bore piping (tapping) at TML#3.
35. Painting shall be carried out for the entire pipe run as per original specification. Inspection
in prior to painting shall be offered for ascertaining the condition of line.
36. Thickness monitoring of entire line shall be performed after 01 Years (from the date of
present inspection) preferably during cold state (shutdown or T/A-2019) to assess the
recorded thickness and establish the exact corrosion rates / remaining life.
37. VCM OPRN to offer the line for random thickness measurement during cold state (shutdown
or T/A-2019) for these high temperature lines to verify the recorded thickness and establish
the exact corrosion rates / remaining life.

Notes:

1. For any replacement activity, Maintenance has to submit the repair procedure, Welding
Procedure Specification (WPS) and Form No. GM-050-14 (inspection requirements for
repair) as per SMP-GM-050 to INSP department for review and approval.
2. During fabrication, stage inspection shall be performed as per inspection requirements of
Form No. GM-050-14.
3. Painting to be carried out as per original specification. The painting procedure and
specification shall be submitted to INSP for review and approval.
4. Ensure the insulation workmanship and adherence to all applicable QA/QC procedures.
Classification: Internal Use

5. VCM operation has to ensure all the requirements / guidelines mentioned as per the
procedure (CGPE-012) for temporary arresting/ repair in the line until permanent repair.